Electric vehicle battery pack having external side pouch for electrical components

ABSTRACT

Electric vehicle battery packs with external side enclosures for containing electrical connectors and other components therein. Each enclosure is sized to support various connectors or other components as desired, and may have a number of openings formed to provide interfaces for connecting various electric vehicle systems to the battery pack. The enclosures may be placed at various locations along one or more sides of the battery pack, and connectors may be routed over an upper surface of a battery pack frame or through a gap formed between the pack frame and cover. Enclosures may be made of any material, including plastic for lower weight applications and metal for improved electromagnetic interference shielding.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication No. 62/760,701, filed Nov. 13, 2018, the disclosure of whichis hereby incorporated by reference herein in its entirety.

INTRODUCTION

The present disclosure is directed to electric vehicle battery packs.More specifically, the present disclosure is directed to electricvehicle battery packs having external side pouches.

SUMMARY

A vital component of current electric vehicles is the battery pack.Conventional battery packs perform a number of functions, includingproviding a protective enclosure to withstand crashes, ground strikes,or other impacts, routing of electrical wires, and containment ofbattery fires.

Battery packs may have a frame that provides the structural rigidity andstrength to withstand impact, a bottom layer, and a top cover or lid.Battery modules are contained within the frame, and the bottom layer andtop cover are attached to the lower and upper surfaces of the frame,respectively, to enclose the batteries.

There are often space constraints limiting the size of battery packs.They should not extend beyond either side of the vehicle for example,and preferably lie only between the front and rear wheels. Further, theyshould be as low profile as possible to minimize any reduction in cabinspace. In order to overcome the space requirements, some batterycomponents of the present disclosure (e.g., electrical connectors,wires, and terminals) are repositioned from the interior of the frame tothe exterior of the frame. One way connections are made betweencomponents inside and outside of a battery frame is to make holes in thesides of the frame. Such holes, however, undesirably weaken the frame.In order to avoid weakening the frame, the present disclosure makesconnections by routing components through a space created between theframe and the top cover or bottom layer.

Accordingly, described herein is a side pouch enclosure for holdingtherein electrical connectors and other components against an outersurface of the frame. In some embodiments, the enclosure has an uppersurface that lies approximately parallel to the upper surface of theframe, so that the top cover can be affixed to both the frame and theenclosure, sealing both. The cover is shaped to leave a gap between theframe and cover where the enclosure is positioned, so that electricalcomponents can be run over the frame, through the gap, and into theenclosure. In this manner, the battery pack may provide electrical powerto vehicle components exterior to the pack via terminals and connectorsin the enclosure, without structurally compromising the battery packframe and while satisfying space constraints within the battery pack.Further embodiments may employ a frame with lowered side walls in areasproximate to the enclosures, creating a gap between the top of thelowered side walls and the cover. Enclosures are placed over or adjacentto this gap, so that electrical components can be extended through thegap and into the enclosure.

The enclosure may be constructed of any material, including a plasticand/or a metal such as aluminum. Additionally, in some embodiments,enclosures of the disclosure may be positioned at any one or morelocations along the outer surface of the frame. For instance, frames maybe constructed with two opposing perpendicular surfaces, and angledsurfaces positioned between the perpendicular surfaces. One or moreenclosures may be placed along any of these surfaces.

BRIEF DESCRIPTION OF THE FIGURES

The above and other objects and advantages of the disclosure will beapparent upon consideration of the following detailed description, takenin conjunction with the accompanying drawings, in which like referencecharacters refer to like parts throughout, and in which:

FIG. 1 is an isometric view of an electric vehicle battery pack assemblyhaving enclosures for housing electrical connectors, and constructed inaccordance with embodiments of the disclosure;

FIG. 2 is a plan view of the assembled electric vehicle battery pack andenclosures of FIG. 1;

FIG. 3 is a magnified plan view of one of the enclosures constructed inaccordance with embodiments of the disclosure;

FIG. 4 is an isometric view showing further details of an exemplaryenclosure constructed in accordance with embodiments of the disclosure;

FIG. 5 is a cross-sectional view of an enclosure opening for electricalconnectors, constructed in accordance with embodiments of thedisclosure; and

FIG. 6 is a side view of an exemplary enclosure constructed inaccordance with embodiments of the disclosure.

DETAILED DESCRIPTION

In one embodiment, the disclosure relates to electric vehicle batterypacks with external side enclosures for containing electrical connectorsand other components therein. Each enclosure is sized to support variousconnectors or other components as desired, and may have a number ofopenings formed to provide interfaces for connecting various electricvehicle systems to the battery pack. The enclosures may be placed atvarious locations along one or more sides of the battery pack, andconnectors may be routed over an upper surface of a battery pack frameor through a gap formed between the pack frame and cover. Enclosures maybe made of any material, including plastic for lower weight applicationsand metal for improved electromagnetic interference shielding.

FIG. 1 shows a battery pack frame assembly 10 with a frame 100 and anumber of enclosures 110, 120, 130 that are attached thereto. Any numberof enclosures 110, 120, 130 is contemplated, but here three suchenclosures 110, 120, 130 are employed. As shown in FIG. 2, theenclosures 110, 120, 130 are each affixed to the outer surface of theframe 100, in various locations as desired. The enclosures 110, 120, 130may be of any size and shape suitable for holding electrical connectorsor terminals therein.

The enclosures 110, 120, 130 may also be made of any material suitablefor forming a pouch or container capable of supporting one or moreelectrical connectors within. As one example, the enclosures 110, 120,130 may be made of a plastic, which may result in weight savings.Plastic enclosures 110, 120, 130 may be formed by injection molding orany other suitable process. As another example, the enclosures 110, 120,130 may be made of a metal such as aluminum, for increased strength andshielding against electromagnetic interference. In some embodiments,metal enclosures 110, 120, 130 may be made of die-cast aluminum of anywall thickness, such as 2.5-4.0 mm wall thickness or any other suitablevalue.

FIG. 3 illustrates further details of one particular enclosure 120,although features shown may apply to any enclosures 110, 120, 130 ofembodiments of the disclosure. As shown in FIG. 3, the enclosure 120 maybe generally elongated, and form a pocket with the outer surface of theframe 100. A first side of the enclosure 120 is flat and is placedagainst the outer surface of the frame 100 to be attached thereto by anysuitable attachment method, such as by an adhesive or screws. A secondside, or the outer side of the enclosure 120, is opposite to the firstside and faces away from the frame. An interior space is defined betweenthe outer surface of the frame 100 and the second side of the enclosure120, to act as a receptacle for any electrical elements. The enclosures110, 120, 130 thus each provide an enclosed space in which one or moreelectrical components may be placed. Wires or other components mayextend over the top of the frame, to be placed in the pocket of theenclosures 110, 120, 130. Two of the enclosures 110, 120 are shown asbeing located on angled sides of the frame 100 (in FIG. 2, the angledsides on the left end of the frame 100, between the horizontal orlengthwise side members 105 and the vertical member 115 on the farleft), and another smaller enclosure 130 is shown as being located at arear surface of the frame 100. The enclosures 110, 120, 130 may belocated at any positions along the frame 100 subject to space and sizerequirements of the vehicle. As shown, the bottom of the enclosure 120includes one or more openings, described in further detail below. Highvoltage lines and other cabling can be routed through the openings andthe connectors can be packaged inside of the enclosure 120. In someembodiments, the high voltage lines that are packaged in the enclosures110, 120, 130 are switched lines. Therefore, in the event of a crashwhere the integrity of the enclosure 120 is compromised, contactorsinside the battery pack can be switched off to prevent short-circuitingof and damage to the battery modules inside of the battery pack.

As with FIG. 3, FIG. 4 illustrates further details of enclosure 120,although features disclosed may apply to any enclosures 110, 120, 130 ofembodiments of the disclosure. As shown in FIG. 4, the enclosure 120 hasflat upper surface 200 that lies flush with the upper surface 210 of theframe 100. In this manner, the upper surfaces of the frame 100 andenclosures 110, 120, 130 have a single height, providing a singlesurface for attachment of the cover and allowing the cover to form aseal over both the frame and the enclosure. It will be understood thatin some embodiments, one or more enclosures 110, 120, 130 can bepositioned to be flush with a lower surface of the frame 100. It willalso be understood that the upper surfaces of the enclosures 110, 120,130 need not necessarily have the same height as the upper surface 210of the frame 100. Instead, the upper surfaces of the enclosures 110,120, 130 may have different heights than the upper surface 210 of theframe 100, and the cover may also have differing elevations in regionscorresponding to the enclosures 110, 120, 130, so as to seal theenclosures 110, 120, 130 even when they are of different heights fromthe frame 100. That is, the enclosures 110, 120, 130 may have heightsdifferent from that of the upper surface 210 of the frame 100, with thecover optionally also having differing heights to compensate for thedifference in elevation between the enclosures 110, 120, 130 and theframe 100, and to seal the enclosures 110, 120, 130 and the frame 100despite these differing elevations.

FIG. 5 is a cross-sectional view of enclosure 120 along with anexemplary opening for electrical connectors, constructed in accordancewith embodiments of the disclosure. FIG. 5 illustrates an exemplaryembodiment in which the upper surface 220 of frame 100 has a differentelevation proximate to enclosure 120, creating an opening or gap betweenthe upper surface 220 and the cover 250 through which electricalconnectors, terminals, or other components may be passed. The enclosure120 may be fastened to cover 250 in any manner, such as by fasteners 140which can be any fasteners, including screws, nails, rivets, bolts,releasable fasteners, or the like. As described above, enclosure 120also includes one or more openings 150 in its lower surface, throughwhich electrical connectors may pass or to which electrical interfacesmay be coupled. Openings 150 may have a metal insert 160 pressedtherein, for electromagnetic interference shielding integrity and/or formore secure fastening of electrical connectors thereto. Insert 160 maybe made of any metal, such as a brass or a steel, and may be pressedinto opening 150 of a cast metallic enclosure 120. The insert 160 may bethreaded if desired, for secure fastening of components thereto.Enclosure 120 may include any number of bosses 170 for receivingfasteners that may be used in securing an electrical terminal or othercomponent in opening 150.

FIG. 6 is a side view of an exemplary enclosure 120 constructed inaccordance with embodiments of the disclosure. Features shown here inconnection with enclosure 120 may be applied equally to any otherenclosure 110, 130 of embodiments of the disclosure. Here, enclosure 120has a lower surface with multiple different elevations, including afirst section 300 with a lower surface oriented at an acute angle withrespect to the upper surface 200, a second section 310 positioned lowerthan the first section 300 and oriented substantially parallel to uppersurface 200, and a third section 320 positioned higher than both thefirst section 300 and second section 310 and also oriented substantiallyparallel to upper surface 200. The particular shape of enclosure 120shown in FIG. 6 may correspond to the sizes and shapes of the variouscomponents contained within, although any shape and dimensions ofenclosure 120 are contemplated. Any number of openings 150 may be formedin any lower or other surface of any of the first, second, or thirdsections 300, 310, 320. As shown, each of the first and second sections300, 310 has one opening 150, although embodiments of the disclosurecontemplate any number of openings 150 in any portion of enclosure 120.Additionally, the size and shape of enclosure 120, and any of itsparticular dimensions, may vary according to any factor, such as thesize and desired position of any components intended to be housedwithin, space constraints within the vehicle, or any other factor.

Enclosure 120 also includes any number of additional openings 180, whichare openings of any shape, formed or cut in any surface of enclosure120. The additional openings 180 may be shaped to receive electricalconnectors, terminals, or other interfaces for placing vehicle or othercomponents in electrical communication with any components containedwithin battery pack assembly 10, such as batteries.

Each enclosure 110, 120, 130, and each of its openings 150, 180 may besized and shaped to accommodate any electrical connectors, terminals, orother components that may be utilized in connection with an electricvehicle. For example, enclosures 110, 120, 130 and openings 150, 180 maybe sized to accommodate fiber distribution units (FDUs) and theirconnectors, direct current fast charge (DCFC) modules or connectors,on-board charger (OBC) components, cables, or connectors, remotediagnostic unit (RDU) components or connectors, and the like.

The foregoing description, for purposes of explanation, used specificnomenclature to provide a thorough understanding of the disclosure.However, it will be apparent to one skilled in the art that the specificdetails are not required to practice the methods and systems of thedisclosure. Thus, the foregoing descriptions of specific embodiments ofthe present disclosure are presented for purposes of illustration anddescription. They are not intended to be exhaustive or to limit theinvention to the precise forms disclosed. Many modifications andvariations are possible in view of the above teachings. For example, anynumber of enclosures may be applied to a battery pack, of any size andconstructed of any nonconductive material. The embodiments were chosenand described in order to best explain the principles of the disclosureand its practical applications, to thereby enable others skilled in theart to best utilize the methods and systems of the disclosure andvarious embodiments with various modifications as are suited to theparticular use contemplated. Additionally, different features of thevarious embodiments, disclosed or otherwise, can be mixed and matched orotherwise combined so as to create further embodiments contemplated bythe disclosure.

What is claimed is:
 1. A side pouch for an electric vehicle battery pack having a frame and a top cover, the side pouch comprising: an enclosure having: a first side for connection to an outer surface of the frame; and a second side extending away from the frame so as to define an enclosed space between the outer surface and the second side; wherein the second side comprises a first lower surface section positioned at a first elevation and a second lower surface section positioned at a second elevation different than the first elevation, and wherein the enclosure is configured to be affixed to the outer surface of the frame and further affixed to the top cover so that the top cover is affixed to both an upper surface of the frame and an upper surface of the enclosure, the top cover and the upper surface of the frame having a gap therebetween for receiving one or more electrical components extending from an interior of the battery pack into the enclosed space of the enclosure.
 2. The side pouch of claim 1, wherein the enclosure comprises one or more of plastic or metal.
 3. The side pouch of claim 2, wherein the metal is aluminum.
 4. The side pouch of claim 1, wherein the second side has a substantially flat upper surface arranged substantially parallel to the upper surface of the frame when the enclosure is coupled to the outer surface.
 5. The side pouch of claim 1, wherein the enclosure is a die-cast or injection molded enclosure.
 6. The side pouch of claim 1, wherein the enclosure further comprises one or more openings formed therein and configured to accommodate one or more connectors for the one or more electrical components.
 7. An electric vehicle battery pack, comprising: a frame defining an interior space within for receiving one or more battery modules, the frame having an outer surface and an upper surface; an enclosure affixed to the outer surface of the frame; a top cover affixed to the upper surface of the frame and an upper surface of the enclosure with a gap between the upper surface of the frame and the top cover, the gap positioned proximate to the enclosure; and one or more electrical components extending from the interior space of the frame into the enclosure through the gap, wherein the outer surface of the frame comprises a first surface oriented along a first direction, the first direction being a lengthwise direction of the frame, a second surface oriented substantially perpendicular to the first direction, and a third surface oriented at an acute angle with respect to the first surface and the second surface.
 8. The battery pack of claim 7, wherein the enclosure comprises one or more of plastic or metal.
 9. The battery pack of claim 8, wherein the metal is aluminum.
 10. The battery pack of claim 7, wherein the enclosure is positioned on the third surface.
 11. The battery pack of claim 7, wherein the enclosure is positioned on the second surface.
 12. The battery pack of claim 7, wherein: the enclosure is a first enclosure; the gap is a first gap; the battery pack further comprises a second enclosure affixed to the outer surface of the frame; and the top cover is affixed to an upper surface of the second enclosure with a second gap between the upper surface of the frame and the top cover, the second gap positioned proximate to the second enclosure.
 13. The battery pack of claim 7, wherein the upper surface of the enclosure is oriented substantially parallel to the upper surface of the frame.
 14. The battery pack of claim 7, wherein the enclosure is a die-cast or injection molded enclosure.
 15. The battery pack of claim 7, wherein the enclosure further comprises one or more openings formed therein and configured to accommodate one or more connectors for the one or more electrical components.
 16. The battery pack of claim 7, wherein the upper surface of the frame has a first elevation proximate to the enclosure and a second elevation removed from the enclosure, the first elevation being lower than the second elevation.
 17. An electric vehicle battery pack, comprising: a frame defining an interior space within for receiving one or more battery modules, the frame having an outer surface and an upper surface; an enclosure affixed to the outer surface of the frame; a top cover affixed to the upper surface of the frame and the upper surface of the enclosure with a gap between the upper surface of the frame and the top cover, the gap positioned proximate to the enclosure; and one or more electrical components extending from the interior space of the frame into the enclosure through the gap, wherein: the enclosure is a first enclosure; the gap is a first gap; the battery pack further comprises a second enclosure affixed to the outer surface of the frame; and the top cover is affixed to an upper surface of the second enclosure with a second gap between the upper surface of the frame and the top cover, the second gap positioned proximate to the second enclosure. 